Blow molded plastic container with inclined mouth and method and apparatus for obtaining same

ABSTRACT

Method and apparatus for blow molding a plastic container with a mouth and neck portion thereof which is inclined or angled with respect to the body portion of the container, plus a plastic container having an inclined or angled mouth and neck portion.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a blow molded, plastic containerhaving an inclined or angled mouth and neck portion, and a method andapparatus for preparing same.

[0002] Blow molded plastic containers, such as those made frompolyethylene terephthalate, are widely used for many applications, suchas, for example, as containers for drinks and cleaning products. Thesecontainers customarily have a straight mouth and neck portion, that is,a mouth and neck portion that are coaxial with the body portion of thecontainer.

[0003] The preparation of these containers generally involves preparinga preform or parison with a mouth and neck portion that are coaxial withthe preform body portion, holding the preform in a blow mold with thepreform mouth and neck portion held coaxial with the preform bodyportion, and forming the desired container in the shape of the blow moldby stretching and blow molding.

[0004] For many applications it is desirable to prepare such a containerwith a mouth and neck portion at an angle to the body portion of thecontainer. However, it is difficult to prepare such an angled mouth andneck portion container by conventional blow molding techniques. Forexample, such techniques may involve expensive and inconvenientmultistage operations where an injected preform is clamped, stretchedand blown in the mold at one station and a blow pin is inserted into themold for blowing and/or compression molding at another station and theneck is bent at a subsequent station or in a subsequent stage ofoperation. Techniques such as this increase the cost of the containerand complicate processing.

[0005] Alternatively, a conventional type apparatus cannot besatisfactorily used to mold a container with an angled mouth and neckportion since to do so would require the mold cavity to be aligned sothat the desired angular neck is appropriately aligned with the blowpin. Significant processing problems result thereby, as well as problemswith the resultant container.

[0006] Accordingly, it is a principal objective of the present inventionto provide a new and improved method and apparatus for obtaining a blowmolded, plastic container with an angled or inclined neck and mouthportion.

[0007] It is a still further objective of the present invention toprovide an improved blow molded, plastic container with an angled orinclined neck and mouth portion.

[0008] It is an additional objective of the present invention to providea method and apparatus as aforesaid which is easy and expeditious to useon a commercial scale, and which simply and conveniently providesimproved containers as aforesaid.

[0009] Further objects and advantages of the present invention willappear hereinbelow.

SUMMARY OF THE INVENTION

[0010] In accordance with the present invention it has now been foundthat the foregoing objects and advantages are readily obtained.

[0011] The present invention provides a method of forming a blow moldedplastic container, preferably polyethylene terephthalate although otherplastic materials can be readily used, said container having a mouth andneck portion thereof which are inclined or angled with respect to thebody portion of the container. The method comprises:

[0012] providing a straight, cylindrical plastic parison or preformhaving a closed base, straight body portion extending therefrom,straight neck portion extending from the body portion, and an openmouth;

[0013] placing said preform in a blow mold having the desired containerconfiguration and clamping or holding the preform in place in the blowmold;

[0014] introducing a stretch rod into the preform and extending saidpreform substantially to the base of the blow mold with said stretch rodto provide an extended preform;

[0015] providing a blow nozzle with an angled face corresponding to thedesired angle of the mouth and neck portion of the container, generallyless than 45° with respect to the longitudinal axis of the container;

[0016] engaging said angled face of the blow nozzle with the open mouthof the preform and bending the open mouth and neck portion of thepreform by the angled face of the blow nozzle to correspond to the angleof the face of the blow nozzle; and

[0017] introducing high pressure air into the extended bent neck preformfrom the blow nozzle to stretch the extended bent neck preform intoconformity with the shape of the blow mold and to provide a biaxiallyoriented container having an angled mouth and neck portion.

[0018] The apparatus of the present invention comprises:

[0019] a blow mold having the desired container configuration forholding in place therein a straight, cylindrical plastic parison orpreform having a closed base, straight body portion extending from thebase, straight neck portion extending from the body portion, and openmouth;

[0020] a stretch rod associated with the blow mold for introduction tothe preform operative to extend the preform substantially to the base ofthe blow mold and provide an extended preform;

[0021] a blow nozzle associated with the blow mold having an angled facecorresponding to the desired angle of the mouth and neck portion of thecontainer, generally less than 45° with respect to the longitudinal axisof the container;

[0022] wherein said angled face of the blow nozzle is operative toengage the open mouth of the preform and bend the open mouth and neckportion of the preform to correspond to the angle of the face of theblow nozzle, and wherein said blow nozzle is operative to introduce highpressure air into the angled mouth and neck of the extended preform tostretch the extended preform into conformity with the shape of the blowmold and to provide a biaxially oriented container having an angledmouth and neck portion.

[0023] The container of the present invention comprises:

[0024] a biaxially oriented, blow molded container prepared from astraight, cylindrical preform or parison, said container having a closedbase, a body portion extending from the closed base, a neck portionextending from the body portion, an open mouth, and a longitudinal axis;wherein said body portion has an upper portion and a lower portion, andin cross section one side of the upper body portion includes a gradual,continuous, curved configuration extending to the angled neck, and theopposed side of the upper portion has a stepped configuration extendingto the angled neck.

[0025] The container of the present invention is desirably polyethyleneterephthalate and may if desired include an amount of post consumerresin (PCR), for example, up to about 75%. Also, if desired thecontainer may be of a multilayer construction. Desirably, the containermay have a threaded neck and an outwardly extending flange in the neckportion beneath the threaded portion.

[0026] Other features and advantages of the present invention willappear hereinbelow.

[0027] BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be more readily understandable from aconsideration of the following illustrative drawings, wherein:

[0029]FIG. 1 is a side view showing the preform positioned in the blowmold, with the stretch rod positioned in the preform and the blow nozzlepositioned above the blow mold;

[0030]FIG. 2 is a view similar to FIG. 1 in a further stage of operationwith the stretch rod extending the preform;

[0031]FIG. 3 is a view similar to FIG. 1 in a further stage of operationwith the blow nozzle coming into engagement with the preform;

[0032]FIG. 4 is a view similar to FIG. 1 in a further stage of operationwith the blow nozzle in full engagement with the preform and bending themouth and neck portion of the preform into the desired angle;

[0033]FIG. 5 is a view similar to FIG. 1 in a further stage of operationshowing the blow nozzle in full engagement with the bent neck and mouthpreform and with an anti-rotation arrangement to prevent rotation of theblow nozzle;

[0034]FIG. 6 is a view similar to FIG. 1 in a further stage of operationshowing the final blow molded container with stretch rod and blow nozzleretracted therefrom, and FIG. 6A is a modification of FIG. 6; and

[0035]FIG. 7 is a side view of the container of the present inventionprepared in accordance with FIGS. 1-6, and FIGS. 7A & 7B are partialsectional views of the wall structure of the container.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0036] Referring to the drawings, FIG. 1 shows a straight, cylindrical,plastic preform or parison 10 having a closed base 12, a straight bodyportion 14 extending therefrom, a straight neck portion 16 extendingfrom the body portion, and an open mouth 18. If desired, the preform hasa threaded neck portion 20 and an outwardly extending flange 22, whichaids in seating the preform 10 in the blow mold 24. The blow mold 24 isclosed on the preform firmly seating the preform in the blow mold.

[0037] Stretch rod 26 is positioned within the preform and blow nozzle28 is spaced above the preform. It is noted from FIG. 1 that blow nozzle28 has an angled face 30 which faces the preform, rather than theconventional flat face. Locking flange 32 is provided in the upperportion of the blow nozzle to lock the assembly in place.

[0038]FIG. 2 shows the stretch rod 26 fully extended in the clampedpreform to extend the preform to the base 34 of the blow mold and toprovide an extended preform 11, while FIG. 3 shows the angled face 30 ofthe blow nozzle 28 moving into engagement with the mouth 18 of thepreform, commencing the bending of the mouth 18 and neck 16 of theextended preform 11 into the desired angled orientation. In FIG. 3, theangled face 30 of the blow nozzle 28 just starts to make contact withthe open mouth 18 of the extended preform. It is noted that blow mold 24includes an angled upper portion 25 to engage the outwardly extendedflange 22 of the preform at an angle which corresponds to the angle ofthe face of the blow nozzle and to insure a proper angled open mouth andneck portion. In FIG. 4, the blow nozzle 28 continues downwardly,bending the open mouth 18 and neck portion 16 of the extended preform toan angular orientation which corresponds to the angle of the angled face30 of the blow nozzle, i.e., less than 45° with respect to thelongitudinal axis of the preform.

[0039]FIG. 5 shows anti-rotation element 36 to prevent rotation of blownozzle 28. High pressure air is then introduced into the extendedpreform through the blow nozzle from a high pressure air source (notshown) to stretch the extended preform into conformity with cavity 38 ofblow mold 24 and form container 40 shown in FIGS. 6-7.

[0040]FIG. 6A is a variation of FIG. 6 and shows the mold and/or moldcavity placed at an angle of from 1 to 45° in relation to the stretchrod. In accordance with the variation of FIG. 6A, at least a portion ofthe mold cavity may conveniently be placed at said angle in relation tothe stretch rod, and the preform appropriately processed at said angle.

[0041] As shown in FIG. 7, container 40 has a closed base 42, a bodyportion 44 extending from the closed base, a neck portion 46 extendingfrom the body portion, and an open mouth 48. The neck portion and openmouth are at an angle of less than 45° with respect to the longitudinalaxis 50 of the container 40. The container body portion 44 has an upperbody portion 52 and a lower body portion 54. In cross-section, one sideof the upper body portion includes a gradual, continuous curvedconfiguration 56 extending to the curved neck, while the opposed side ofthe upper portion has a stepped configuration 58 extending to the curvedneck. Container 40 also has a threaded neck 60 and outwardly extendingflanges 62. In addition, the container is biaxially oriented. Thecontainer can have a multi-layer wall structure as shown in FIG. 7A, ora single layer wall structure as shown in FIG. 7B.

[0042] After completion of the blow molding operation, the stretch rodfollowed by the blow nozzle is retracted from the newly formedcontainer, the blow mold is opened, and the newly formed container isremoved.

[0043] Preferably, the plastic is polyethylene terephthalate; however,other suitable thermoplastic plastics may be readily used alone or incombination or in a multilayered configuration. For example,polyolefins, polyethylene naphthalate, polyvinyl chloride, and others.

[0044] It is to be understood that the invention is not limited to theillustrations described and shown herein, which are deemed to be merelyillustrative of the best modes of carrying out the invention, and whichare susceptible of modification of form, size, arrangement of parts anddetails of operation. The invention rather is intended to encompass allsuch modifications which are within its spirit and scope as defined bythe claims.

What is claimed is:
 1. Method of forming a blow molded, plasticcontainer with a mouth and neck portion thereof which is inclined orangled with respect to the body portion of the container, whichcomprises: providing a straight, cylindrical plastic preform having aclosed base, straight body portion extending therefrom, straight neckportion extending from the body portion, and open mouth; placing saidpreform in a blow mold having the desired container configuration andholding said preform in place in the blow mold; introducing a stretchrod into the preform and extending said preform substantially to thebase of the blow mold with said stretch rod to provide an extendedpreform; providing a blow nozzle with an angled face corresponding tothe desired angle of the mouth and neck portion of the container;engaging said angled face of the blow nozzle with the open mouth of thepreform and bending the open mouth and neck portion of the preform bythe angled face of the blow nozzle to correspond to the angle of theface of the blow nozzle; and introducing high pressure air into theextended bent neck preform from the blow nozzle to stretch the extendedbent neck preform into conformity with the shape of the blow mold and toprovide a biaxially oriented container having an angled mouth and neckportion.
 2. Method according to claim 1, wherein the angled face of theblow nozzle is less than 45°, and wherein said angled face bends theopen mouth and neck portion of the preform to a corresponding angle ofless than 45°.
 3. Method according to claim 1, including providing aplastic preform of polyethylene terephthalate.
 4. Method according toclaim 1, including providing a preform which contains post consumerresin.
 5. Method according to claim 1, including providing amulti-layered preform.
 6. Method according to claim 1, includingproviding a preform which includes a threaded neck portion and anoutwardly extending flange portion beneath the threaded neck portion. 7.Method according to claim 6, wherein said open mouth and neck portion ofthe preform is bent by the angled face of the blow nozzle so that theoutwardly extending flange of the preform engages an angled portion ofthe blow mold.
 8. Method according to claim 1, wherein the preform isplaced in a mold cavity of the blow mold, and wherein the mold cavity isplaced at an angle of from 1 to 45° with respect to the stretch rod. 9.Apparatus for forming a blow molded, plastic container with a mouth andneck portion thereof which is inclined or angled with respect to thebody portion of the container, which comprises: a blow mold having thedesired container configuration for clamping or holding a straight,cylindrical plastic parison or preform having a closed base, straightbody portion extending from the base, straight neck portion extendingfrom the body portion, and open mouth; a stretch rod associated with theblow mold for introduction into the preform operative to extend thepreform substantially to the base of the blow mold and provide anextended preform; and a blow nozzle associated with the blow mold havingan angled face corresponding to the desired angle of the mouth and neckportion of the container; wherein said angled face of the blow nozzle isoperative to engage the open mouth of the preform and bend the openmouth and neck portion of the preform to correspond to the angle of theface of the blow nozzle, and wherein said blow nozzle is operative tointroduce high pressure air into the angled mouth and neck of theextended bent neck preform to stretch the extended bent neck preforminto conformity with the shape of the blow mold and to provide abiaxially oriented container having an angled mouth and neck portion.10. Apparatus according to claim 9, wherein the angled face of the blownozzle is less than 45°, and wherein said angled face of the blow nozzleis operative to bend the open mouth and neck portion to a correspondingangle of less than 45°.
 11. Apparatus according to claim 9, wherein theplastic preform is polyethylene terephthalate.
 12. Apparatus accordingto claim 9, wherein the plastic parison contains post consumer resin.13. Apparatus according to claim 9, wherein the plastic preform is amultilayered preform.
 14. Apparatus according to claim 9, wherein theplastic preform includes a threaded neck portion and an outwardlyextended flange portion beneath the threaded neck portion.
 15. Apparatusaccording to claim 14, wherein the blow mold includes an angled portioncorresponding to the angled face of the blow nozzle, wherein the angledface of the blow nozzle bends the open mouth and neck portion of thepreform so that the outwardly extending flange of the preform engagesthe angled portion of the blow mold.
 16. Apparatus according to claim 9,wherein the blow mold includes a mold cavity for receiving the parison,wherein the mold cavity is placed at an angle of from 1 to 45° withrespect to the stretch rod.
 17. A biaxially oriented plastic containerprepared from a straight, cylindrical preform, which comprises a closedbase, a body portion extending from the closed base, a neck portionextending from the body portion, an open mouth, and a longitudinal axis;wherein said open mouth and neck portion are at an angle of less than45° with respect to the longitudinal axis; and wherein said body portionhas an upper portion and a lower portion, and wherein in cross sectionone side of the upper body portion includes a gradual, continuous curvedconfiguration extending to the angled neck, and the opposed side of theupper portion has a stepped configuration extending to the angled neck.18. Container according to claim 17, wherein said container ispolyethylene terephthalate.
 19. Container according to claim 17, whereinsaid container contains post consumer resin.
 20. Container according toclaim 17, wherein said container is multilayered.
 21. Containeraccording to claim 17, wherein said neck portion includes a threadedportion and an outwardly extending flange beneath the threaded portion.